Handling and dispensing system and apparatus for cylindrical objects

ABSTRACT

A dispensing system apparatus for storing and dispensing cylindrical objects such as rolls of floor covering has a sloped rack on which the rolls are supported and further contains serially arranged dispensing and retaining blades for dispensing a roll near the leading edge of the rack on to a portable pallet carried by a conventional lift truck while retaining the roll behind it and then, by manipulation of the dispensing and retaining means, move the next cylindrical object into a position for dispensing while retaining in the storage facility a plurality of serially arranged cylindrical objects.

CROSS-REFERENCE TO RELATED APPLICATION

This is a division, of application Ser. No. 367,799 filed June 7, 1973,now U.S. Pat. No. 3,951,276 issued on April 20, 1976.

SUMMARY OF THE INVENTION

This invention relates to an improved handling system and dispensinghaving particular utility in the handling and storage of bulky and heavycylindrical objects such as floor covering rolls and the like. Oneaspect of the invention relates to an improved dispensing apparatuscombined with storage means. Another aspect of the invention relates toimprovements and means for storing and dispensing cylindrical objectsone at a time. Another aspect of the invention deals with a systemincluding handling means for receiving the dispensed object. Further,the dispensing and handling system provides for storage of bulky and/orheavy cylindrical objects in a minimum of space. Without prejudice tobroader coverage the invention will be described in connection with afloor covering roll storage and dispensing apparatus and handlingsystem.

The present system contemplates storage of a number of cylindricalobjects such as rolls of floor covering one behind another with axesparallel on a support means with a sloped bottom, such as sloping guiderails to provide gravity type of feed of the objects from the storagemeans.

There is provided in combination with such a storage means a pair ofserially arranged detent members; the forward member being adjacent theleading or downhill edge of the sloping support with the rearward memberbeing spaced at least one roll width away from the forward member in thedirection of the storage means. The detent members can be moved into andout of engagement with roll material whereupon the roll will be retainedor released at the point of discharge, respectively, to a portablepallet means for transporting it away from the storage means.Concurrently with this retention or release function of the forwardmember means, the second member or members retain a single roll or thebalance of the cylindrical objects within the storage means when theforward means is releasing one and vice versa. In this manner, one rollat a time is released by the forward member while all the remainingrolls are detained by the rearmost member or members.

The system includes a simple dispensing device including at least a pairof blades mounted approximately one roll diameter apart along a shaftand projecting radially or diametrally from the shaft an angle of 90°relative to each other. In this manner, rotating the shaft 90° positionsone of the blades so that a roll can and does pass over it and positionsthe other blade so as to retain a roll uphill of it. The portable palletmeans includes a skeletal frame having means for alignment with thebottom edge of the storage means and stop means to receive and retain adispensed cylindrical object. Additionally, this means is designed toreceive the prongs of a conventional fork lift truck to render thepallet portable and mobile.

BACKGROUND OF INVENTION

In a typical roll storage facility whether for receipt of themanufactured product or for distribution of the roll product atwholesale or retail levels, it is customary to store the rolls in pileson some support means where the axes of the rolls are parallel andtransverse to the access aisles providing space for entry and removal ofthe rolls from the storage means. Where the product is comprised of verywide and bulky rolls of large diameter, such as carpet, or wide rolls ofconsiderable weight such as linoleum or equivalent floor coverings, itis impossible to handle the rolls without the assistance of somemechanical means. Since the axes and hence, the hollow core of the rollsare transverse to the handling space an obvious device is the fork lifttruck since the prongs of the conventional fork lift can readily beinserted into the cores and the rolls lifted, lowered and transportedfrom place to place with relative ease. Because the fork enters the rollcore axially it is apparent that access to the roll storage means mustbe of such expanse as to provide for maneuvering of the lift truck foraxial entry of the fork into the roll cores and also to permitmaneuvering of the truck with the axial width of the roll extendingparallel to the truck axis. Conventionally, a working space ofapproximately 16 feet in width, i.e. extending outwardly from theworking side of the storage means, is required to enable a fork lifttruck to maneuver in the process of handling the roll material.

When it is considered that manufacturing and sale of floor covering andsimilar roll form material is virtually a continuous operation, it isapparent that immense storage facilities must be provided to handleinventories of manufactured but unsold materials. When the spacerequirements for storage of the material are increased by the necessityof large areas of handling space such as 16 foot aisles, it can readilybe seen that any storage and handling system and means that facilitatesreduction in any area, storage or handling, represents a substantialadvantage in the art.

The present invention then deals with the very vital problem of reducingcosts and size of storage area by as much as 50% of the handling arearequired and in effecting this result without the expenditure ofconsiderable sums of money for highly sophisticated and specializedhandling equipment and storage facilities. In addition the invention, tobe described in detail, is readily adaptable to existing handling andstorage facilities.

Other objects, advantages and features of the inventive concept willbecome apparent from the following disclosure when read in conjunctionwith the drawings wherein:

FIGS. 1a and 1b are illustrations of a typical prior art storagefacility in a 100 × 200 foot building as compared with the storagefacility utilizing the present invention;

FIG. 2 is an isometric schematic illustration of a rack for storing anddispensing rolls of carpeting to a pallet or similar attachment on theforks of a lift truck;

FIG. 3 is an isometric view of the roll receiving and transportingpallet used in conjunction with the storage rack of FIG. 2;

FIG. 4 is a side schematic view of a part of the apparatus of FIG. 1showing the blades in position when the front roll is retained;

FIG. 5 is a side schematic view similar to FIG. 4 but showing theposition of the blades when the front roll is being dispensed and theroll immediately behind it retained;

FIG. 6 illustrates schematically an alternative drive means for theshaft 21, while

FIG. 7 schematically illustrates a further modified form of dispensingand retaining mechanism.

DETAILED DESCRIPTION

In FIG. 2 there is illustrated a storage facility for rolls of floorcovering comprising a storage rack 10. Rack 10 includes verticalstructural columns 1, cross members 3 and roll support rails 5 and 5'.The rails 5 and 5' are disposed at a slight angle approximately 5° tothe horizontal toward the front or working face of the rack. In thepresent system it is desired to dispense the rolls by gravity, one at atime, from the storage rack 10 to a handling pallet 20 which is mountedon the forks of a conventional lift truck or the like.

The portable pallet 20 is comprised of a pair of conventional box beammembers 7 and 7' fixed in spaced apart parallel relation by a pair ofinverted channel members 9, 9' the latter being similar and spaced apartin the same parallel relation as are the rails 5,5' of storage rack 10.The right-hand ends of the channel members, as viewed in FIG. 3, areprovided with upstanding roll stop means 11, 11'. The most conventionalmeans of assembly of the skeletal pallet is by welding at the variousconnection points. One particular relationship that is of importance isthe spacing not only between inverted channel members 9, 9' noted above,but the spacing between box members 7, 7'. This spacing is such as tocorrespond to the distance between the prongs of a conventionalfork-lift truck so that the prongs may enter the hollow interiors ofmembers 7 and 7' for lifting and maneuvering the pallet 20.

As shown in FIG. 2, the racks additionally comprise several spacedvertical tiers of product supporting rails. The limitation on the numberof tiers and/or height of the racks is that imposed solely by thelimitations on lifting ability and reach of the lift trucks used inhandling pallet 20.

As is further shown in FIG. 2, the cross members 3 in each tier carrythe rolled product separating and dispensing means 30 which is shownonly as applied to one tier for illustrative purposes.

A shaft 21 is provided between the fore and aft cross member 3. Thisshaft is advantageously mounted in bearings 15, 17 which are in turnsecured (as by a conventional pillow block construction) to the crossmembers 3, 13. At the forward end of the shaft adjacent the leading orworking face of the rack 10 (illustrated as forward cross bar 3) is afurther gear and shaft assembly 19 which meshes with a gear, notidentified, keyed on shaft 21 to provide a means to rotate the shaft 21.The shaft 19 is in turn coupled to a reversible electric motor by afurther shaft and gear assembly 23. Adjacent the same forward edge ofrack 10 is the first or forward dispensing or retaining blade 27 whichis arranged to project radially from the shaft 21 in a planeapproximately perpendicular to the rail members 5, 5'. Incidentally, theshaft is positioned to lie in either the same plane or preferably in aplane slightly beneath and parallel to the upper surfaces of rails 5, 5'so that the rolls may freely roll down rails 5, 5'.

Spaced rearwardly from the dispensing blade 27 is a second retainingblade 29 which projects from the shaft 21 radially and is rotated to anangular position of 90° from the position of the forward blade 27. Thuswhen blade 27 is projecting upwardly above the surfaces of rails 5, 5'the blade 29 is disposed below the surfaces and vice versa.

As shown in FIG. 4, the forward blade 27 acts as a stop for the foremostroll R, so long as the blade is in its uppermost position. When,however, the shaft 21 is rotated through an angle of 90°, the blade liesbelow the surface of rails 5, 5' and roll R, and is released to progressby gravity onto the pallet 20.

Referring still to FIGS. 2 and 4, at the same time that the dispensingblade 27 is rotated 90° to dispense the forwardmost roll R, theretaining blade 29 is turned to an upright position where it engages thesecond roll R₂, and prevents same from rolling or otherwise advancingalong the rails 5, 5' towards the working face of the rack 10. Thisretaining function of blade 29 continues until such time as the shaft 21is again turned 90° whereupon the roll R₂ moves over the downturnedblade 29 and advances by gravity toward the working edge, to where itreplaces roll R₁, and is held in ready position by the forward ordispensing blade 27 thus returning the system to its original condition.

In the described structure utilizing blades of the type shown positionedat 90° apart the drive may be by the disclosed electric motor 25 drivingshaft assembly 23. It is also possible to utilize a hydraulic operatorin the form of a reciprocating motor as shown in FIG. 6. In thisarrangement, shaft 21 is connected to a crank 31 which in turn isconnected in a conventional manner to the double acting reciprocatingmotor 33 having one end 35 anchored to cross member 3. The power sourceand operating controls for motor 33 are purely conventional and need notbe described in detail. Thus, as motor 33 is operated the reciprocatingmotion is transmitted through crank 31 to shaft 21 to rock the shaftback and forth between the two 90° positions.

FIG. 7 shows modified blades extending diametrically from the shaft.When using the radial blades of FIG. 2 et seq., the shaft 21 is rockedback and forth between two positions angularly spaced 90° apart.

However, in the FIG. 7 disclosure, since each blade 47 and 49 projects180° in both directions from the shaft the shaft may be rotated in onedirection only, stopping at 90° intervals to produce the same results asthe FIG. 2 et seq. structure without the necessity of reversing thedirection of movement of shaft 21. Thus, the diametral blade arrangementof FIG. 7 lends itself to operation by unidirectional electric motor andmuch more simplified controls. In this case also a simple chain andsprocket drive comprising sprockets 37 and 39 and chain 41 may be drivenby motor 45.

It should be noted that in both the FIG. 2 et seq. and FIG. 7 versionsof the dispensing and retaining device, the axial spacing of blades 27and 29, or 47, 49, as the case may be, along the shaft 21 isapproximately equal to the anticipated diameter of the rolled productR₁, R₂, R₃ etc., so that as the blade 29 or 49 moves to the up oroperative position it will move into the space at the bottom between therolls R₁, R₂, etc., and separate the adjacent rolls without damage tothe products. In most instances, this distance can be standardizedbecause the particular industry such as carpeting or floor coveringindustry standardizes on roll size. Where, however, the system is to beused in handling and storing rolls which may vary in size, i.e.diameter, the blades 27 and 29 and 47 and 49, as the case may be, may beadjustably attached to the shaft.

Having described the invention in detail, it will be apparent thatvarious modifications will occur to those skilled in the art, hence theinvention is limited only as defined in the appended claims, wherein:

What is claimed is:
 1. A space saving system for storing and handlingcylindrical stock such as floor coverings and the like comprising aplurality of identical racks in rows so arranged as to define corridorsbetween every two adjacent rows to admit an object carrying movablepallet to move between said rows along said corridor, said racks havinga support structure sloping toward the working face of said rack facingsaid corridors for receiving and storing a plurality of pieces ofcylindrical stock in serial order with the axes of the pieces parallelto each other and also to a plane passing through the working face ofthe rack, a first and second rotary retention means in the form ofsingle thin blades radially extending from and fixed to a commonrockable shaft and having their wide faces traversed to said cylindricalstock on said rack engaging and holding said lowermost cylinder in saidrack, said second retention means being displaced angularly at 90° tosaid first means and positioned inwardly in the face of the rack adistance at least equal to the diameter of one cylindrical articleengageable with the next succeeding piece of cylindrical stock of saidcylindrically pieces thereof, a common drive means interconnecting saidretention means to position said first retention means in an inoperativeposition to free said lowermost cylinder for discharge from said rackand simultaneously to position said retention means in operativeposition to hold the next succeeding piece of cylindrical stock inposition in said rack and vice versa, said drive means mounted on saidracks and positioned out of the path of movement of said pieces ofcylindrical stock from the rack and also the path of movement of apallet along said corridors; and a portable pallet means including askeletal frame having means to receive the prongs of a fork lift truckmoveable along said corridors between facing racks and of a width toreceive a single piece of said cylindrical stock positioned adjacent theworking face of the storage rack for receiving the lowermost piece ofcylindrical stock by gravity discharge from said rack upon operation ofsaid retention means to free same, said pallet means including stopmeans positioned in a plane parallel to the longer axis of said palletmeans for holding said first piece of cylindrical stock on said palletmeans for subsequent transport in a direction parallel to its axis whenit is discharged onto said pallet means.
 2. A storage system forcylindrial stock as defined in claim 1 wherein said racks include aplurality of vertically-aligned tiers each tier having a sloping bottomto receive said cylinders to stock.
 3. A system for storing cylindricalstock as defined in claim 1 wherein the bottom slopes at an angle of notless than 5° from the horizontal toward the working face of the rack. 4.A system for storing cylindrical stock as defined in claim 1 whereinsaid drive means includes a reversible motor.